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PaRTS MaNUaL
aLL TIME GIRTH WELdER
BGW-1000 BGW-2000
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Whenever you request replacement parts or information on this equipment, always supply the information you have
recorded above.
INSTRUCTIONS
Model Number
Serial Number
Date of Purchase
a dIVISION OF WELd TOOLING CORPORaTION
280 TECHNOLOGY dRIVE
PHONE: 1-412-331-1776
aNd
CaNONSBURG, PENNSYLVaNIa
http://www.bugo.com
LIT-BGW-IPM-1209
15317-9564 USa
FaX: 1- 412- 331- 0383
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Related Manuals for BUG-O BGW-1000
Summary of Contents for BUG-O BGW-1000
- Page 1 INSTRUCTIONS PaRTS MaNUaL aLL TIME GIRTH WELdER BGW-1000 BGW-2000 Please record your equipment identification information below for future reference. This information can be found on your machine nameplate. Model Number Serial Number Date of Purchase Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above.
- Page 2 SAFETY PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. ELECTRIC SHOCK can kill. EQUIPMENT DAMAGE POSSIBLE. 1) The equipment is not waterproof. Using the unit in a wet environment may result in serious injury.
- Page 3 HIGH FREQUENCY WARNINGS SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA, TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY TO STRIKE AN ARC. WARNING: HIGH FREQUENCY CAN EFFECT MACHINE OPERATION AND THEREFORE, WELD QUALITY. Read the precautions below before installing and using the equipment. PRECAUTIONS: 1) Some plasma or welding cables are strong sources of high frequency interference.
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Page 4: Table Of Contents
BUG-O ALL TIME GIRTH WELDER INSTRUCTIONS AND PARTS MANUAL TABLE OF CONTENTS PAGE PAGE 5 ... General Description 5 ... General Description / Single and Double Sided Welding 5 ... General Description / Welding Process 5 ... Technical Specifications 6 ... Key Components 6 ... -
Page 5: General Description
BGW-2000 Designed with the same principle as BGW-1000, but with an “A” frame that carries one set of weld head on each side. One side, referred to as the master, can be used by itself for one side welding. The second side (slave) is hinged to the top of the master frame and is used when welding two sides. - Page 6 KEY COMPONENTS Main Frame The Main frame of the girth welder is constructed of structural steel and square tube members. The slide square tube mechanism with locking pins and pin holes is used to adjust the frame height for welding different sizes of shell plates.
- Page 7 110V Aux Version Control System The Bug-o All Time BGW sold in the markets using 110V are equipped with a special circuitry to provide 110V aux outlet and lamps. The 110V outlet socket is identified with yellow color instead of blue as in the...
- Page 8 Accurately adjust speed travel speeds (cm/min) of the girth welder. The speed can be monitored at the control display. U.S. version of Bug-o All Time BGW would be programmed to display travel speed in IPM (inch per minute). Normal / full speed travel switch...
- Page 9 “Flux recovery vacuum” switch (S2) Turns on the power of the vacuum for flux recovery. Inverter ON/OFF “Lighting switch” Push button switches to power on / off the inverter. Switch on the hurricane lamp for night operation. CAUTION: Switching the inverter on and off in Emergency stop short interval could cause damage to the inverter.
- Page 10 Heavy Duty Blower Type Vacuum / Filter System Flux Recovery System (OPTIONAL) Must be Sealed The Bug-o All Time BGW may be equipped with a heavy duty blower Vacuum type vacuum for multi shifts continuous operation. Such vacuum sys- Vent Flux...
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Page 11: Installation And Operations
Electric flux winch A 220VAC power winch is mounted on a “L” post at the roof of the girth welder, it provides a max. lifting capacity of 375 lbs. (170 kg) to lift welding flux up to 98' (30m) below the girth welder. Please refer to the Winch MW170 manual for details. - Page 12 Remove the location pins of the four square tube members of the BGW, use the lifting device to adjust the height of the BGW to the size of the shell plate. Relock the location pins when the appropriate position (pin holes) is found and apply a locking pin to secure the location pin at the appropriate pin holes on the square tubes.
- Page 13 Once the main frame is setup correctly, mount the cable hanger (1), safety hand rail (2), flux lifting post (3) and electric flux winch (4), on the frame roof. Mount the NA-3 control and master control to the control mounting plate at the right hand side of the frame. Master Control Connections There are nine sets of receptacles (eight sets for some models) at the side of the control panel, each receptacle is...
- Page 14 Input Connection WARNING! Only a qualified electrician should connect the input leads to the BGW-1000. Connections should be made in accordance with all local and national electrical codes. Connect the three phase supply line (380V for standard BGW, 240V / 440V for special version) to L1, L2, L3 and ground to the input lug of the 3-phase circuit breaker inside the electrical cabinet as illustrated to the input supply connection diagram below.
- Page 15 Test all the switches on the master control panel and monitor the LEDs. NOTE: The BGW master control is powered by 220V/1ph VAC, please check for first time operation. CAUTION: After switching off the inverter, please wait for at least 3 minutes before switching it on again. Quick repetitions to switch the inverter on and off could damage the inverter due to the residual volt- age.
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Page 16: Welding Procedure Guidelines
WELDING PROCEDURE GUIDELINES Joint Design 2/38 blunt side 2-3 mm gap: 0mm Typical Welding Parameters (for 3.2mm wire) Wall Thickness Voltage(V) Amp(A) Travel Speed Torch Angle Shell Course .4''-.55'' 26-27 320-350 15-17 in/min 15°-20° (10-14 mm) 380-420 (mm/min) 27-29 450-480 19-20 in/min 480-520 (mm/min) .63''-.71''... - Page 17 WELDING PROCEDURE GUIDELINES, CONTINUED Wire Diameter F2.4mm; F = Front; B = Back WTδ δ δ δ δ =12 Current(A) Voltage(V) Travel Speed F(1) .5'' (12mm) 380~400 25~26 20~24 in/min 50~60 cm/min B(1) .5'' 12mm 360-380 25~26 20~24 in/min 50~60 cm/min F(1) .5'' 12mm 22~26 in/min 55~65 cm/min...
- Page 18 WELDING PROCEDURE GUIDELINES, CONTINUED B) Shell Wall Thickness .3'' (8mm) WTδ δ δ δ δ =8 Current(A) Voltage(V) Travel Speed F(1) .3'' (8mm) 31~33 in/min 80~85 cm/min B(1) .3'' 8mm 31~33 in/min 80~85 cm/min F(2) .3'' 8mm 33~37 in/min 85~95 cm/min B(2) .3'' 8mm 33~37 in/min 85~95 cm/min...
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Page 19: Troubleshooting
TROUBLESHOOTING Problems Possible Causes Recommended Action Improper control or feeding Lincoln welding control or power supply 1. Check all fuses. of welding wire. is abnormal. 2. Check Lincoln control switch is “on”and polarity switch on the power supplies must be in “+” or “-“. 3. - Page 20 TROUBLESHOOTING, CONTINUED Problems Possible Causes Recommended Action Main frame travels at 1. Welding control faults. 1. Check welding control. manual mode but not under auto mode. * Please refer to Lincoln NA3 for details. Vacuum fails to recover flux. 1. Both flux valves are open. 1.
- Page 21 MAINTENANCE Flux belt must be properly adjusted, during operation, the latex flux belt should be snug and both roll centerlines are parallel. Overly tight belt tension would cause the rollers to skew bending both rollers and cause the belt to roll off.
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Page 22: Girth Welder / Parts List
GIRTH WELDER / PART S LIST ITEM PART NUMBER DESCRIPTION BGW-1030 MIDDLE FRAME BGW-1032 FLUX HOPPER BGW-1033 REEL BGW-1034 HEX SOCKET CAP SCREW M12X35 BGW-1036 FLAT WASHER 12 BGW-1037 REEL BRACKET BGW-1038 CONNECTION PIN BGW-1039 STAINLESS STEEL SPRING CLIP BGW-1041 FRONT CLAMP BGW-1042 HEX SOCKET CAP SCREW M10X25... -
Page 23: Girth Welder / Exploded View
GIRTH WELDER / EXPLODED VIEW... -
Page 24: Control Box Assembly / Parts List
CONTROL BOX ASSEMBLY / PARTS LIST ITEM PART NUMBER DESCRIPTION BGW-1101 RESIDUAL CURRENT PROTECTOR BGW-1102 FUSE E931-32 BGW-1013 INVERTER DRIVE (ABB) ACS350-01E-07A5-2 BGW-1103 INSULATION PANEL BGW-1104 SCREW M4*10 BGW-1106 INSTALLATION RAIL BGW-1014 SPEED DISPLAY HB5735B 0~10V 0~299 BGW-1107 SPEED POTENTIOMETER 3590S-103L BGW-1108 LED AD16 24V DC BGW-1109... -
Page 25: Control Box Assembly / Exploded View
CONTROL BOX ASSEMBLY / EXPLODED VIEW... -
Page 26: Guide Wheel Assembly / Parts List
BGW-1087 GUIDE WHEEL ASSEMBLY / PARTS LIST (please refer to the drawing in p.23) Item No Descriptions Part No. Bracket BGW-1171 Sleeve BGW-1172 Direction plate BGW-1173 Copper Bushing BGW-1174 Inside Sleeve BGW-1176 Lead Screw BGW-1177 Screw GB/T77-1985 M6*4 1 BGW-1178 Nut Lid BGW-1179 BGW-1181... -
Page 27: Guide Wheel Assembly / Exploded View
BGW-1087 GUIDE WHEEL ASSEMBLY / EXPLODED VIEW... -
Page 28: Operations Schematic
OPERATIONS SCHEMATIC... -
Page 29: Wiring Diagram
WIRING DIAGRAM... -
Page 30: Warranty
SERIAL NO. ________________________ DATE PURCHASED: _________________ FOR A PERIOD OF TWELVE (12) MONTHS FROM DELIVERY, BUG-O SYSTEMS WARRANTS TO THE ORIGINAL PURCHASER (DOES NOT INCLUDE AUTHORIZED DISTRIBUTORS), THAT A NEW MACHINE IS FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP AND AGREES TO REPAIR OR REPLACE, AT ITS OPTION, ANY DEFECTIVE PARTS OR MACHINE. THIS WARRANTY DOES NOT APPLY TO MACHINES, WHICH AFTER OUR INSPECTION, ARE DETERMINED TO HAVE BEEN DAMAGED DUE TO NEGLECT, ABUSE, OVERLOADING, ACCIDENT OR IMPROPER USAGE.
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